US-12626611-B2 - Using cloud-based data for industrial automation system training

US12626611B2US 12626611 B2US12626611 B2US 12626611B2US-12626611-B2

Abstract

A cloud-based performance enhancement service captures and collects data relating to interactions of users with industrial automation systems of multiple industrial customers for storage and analysis on a cloud platform. The service employs a performance enhancement component that analyzes the data to facilitate determining correlations between certain user interactions and favorable performance of an industrial automation system, determining user interactions that are less favorable or unsafe, determining alternative actions that a user can take to achieve a same or similar preferred operational result, generating recommendations relating to the alternative actions, determining or designing components or techniques that can automate a preferred user action, determining improved user assignments in connection with the industrial automation system, and/or generating training modules or presentations based on preferred user actions that can be used to train users to more efficiently interact with an industrial automation system to achieve improved system performance.

Inventors

Juan Asenjo
Edward Alan Hill
Sal Conti
John Strohmenger
Stephen Nawalaniec
Bradford H. Hegrat
Joseph A. Harkulich
Jessica Lin Korpela
Jenifer Rydberg Wright
Rainer Hessmer
John Dyck

Assignees

ROCKWELL AUTOMATION TECHNOLOGIES, INC.

Dates

Publication Date: 20260512
Application Date: 20230505

Claims (20)

1 . A system, comprising: at least one memory that stores computer-executable components; and at least one processor, operatively coupled to the at least one memory, that executes the computer-executable components, the computer-executable components comprising: a collection component configured to receive a set of data associated with a set of devices of an industrial automation system; and a performance enhancement component configured to generate a simulation model representative of the industrial automation system based on a first simulation of performance of a first action by a user as part of a work task being performed by the user under a first work instruction in connection with operation of the industrial automation system, wherein the first simulation is determined based on a first result of a first analysis of at least a portion of the set of data, wherein the performance enhancement component is configured to determine a modification of the first work instruction to a second work instruction relating to automated performance of a second action as part of the work task, and generate a modified simulation model representative of a modified industrial automation system, comprising the modification of the first work instruction to the second work instruction for modified operation of the industrial automation system, based on a second simulation of the automated performance of the second action by a subset of devices as part of the work task under the second work instruction, wherein the modification and the second simulation are determined based on a second result of a second analysis of modification data relating to the modification and the portion of the set of data, wherein the performance enhancement component is configured to determine a predicted response of the modified industrial automation system under a set of operating conditions, based on operation condition data applied to the modified simulation model relating to the second work instruction, wherein the operation condition data is representative of the set of operating conditions, wherein, in response to determining, based on the predicted response of the modified simulation model, that, under the second work instruction, the subset of devices is able to emulate the performance of the work task by the automated performance of the second action and improve operational performance of the industrial automation system over the first work instruction, the performance enhancement component is configured to replace the first work instruction with the second work instruction to have the automated performance of the second action by the subset of devices, under the second work instruction, as part of the performance of the work task, in place of the user, and wherein the subset of devices is part of or incorporated into the set of devices.
2 . The system of claim 1 , wherein, based on the second result of the second analysis of the modification data and the portion of the set of data, the performance enhancement component is configured to design machine-executable code that enables the automated performance of the second action by the subset of devices, based on the machine-executable code, in place of the user, in accordance with the second work instruction, wherein the portion of the set of data is representative of, and is obtained from monitoring of, the performance of the first action by the user, comprising an interaction of the user with the industrial automation system during the performance of the work task by the user, that occurred prior to the design of the machine-executable code, and wherein, to facilitate a determination of the design, the performance enhancement component is configured to simulate operation of the subset of devices, based on the machine-executable code, to verify that the automated performance of the second action by the subset of devices is in accordance with a defined performance criterion relating to a defined favorable performance of the industrial automation system.
3 . The system of claim 2 , wherein the performance enhancement component is configured to generate the machine-executable code based on the design of the machine-executable code, and wherein the subset of devices are implemented in the industrial automation system for the automated performance of the second action based on the machine-executable code.
4 . The system of claim 1 , wherein, based on the first result of the first analysis of at least the portion of the set of data, the performance enhancement component is configured to determine a correlation between the performance of the first action by the user, as part of the performance of the work task associated with the operation of the industrial automation system, and a defined favorable performance of the industrial automation system.
5 . The system of claim 1 , wherein the work task is a first work task, wherein the portion of the set of data is a first portion of the set of data, and wherein, based on a third analysis of a second portion of the set of data, the performance enhancement component is configured to determine that a second performance of a third action as part of a second work task being performed by the user or another user in connection with the operation of the industrial automation system results in a defined unfavorable operational performance of the industrial automation system.
6 . The system of claim 5 , wherein the modification is a first modification, wherein the performance enhancement component is configured to determine a second modification relating to the second performance of the third action as part of the second work task, based on the third analysis, to facilitate improvement of the operational performance of the industrial automation system.
7 . The system of claim 6 , wherein the modified simulation model is a first modified simulation model, wherein the predicted response is a first predicted response, wherein the set of operation conditions is a first set of operating conditions, wherein the performance enhancement component is configured to modify the first modified simulation model of the industrial automation system, based on the second modification, to generate a second modified simulation model, wherein the second modified simulation model facilitates simulation of a second modified industrial automation system that corresponds to implementation of the second modification in the modified industrial automation system, wherein the performance enhancement component is configured to determine a second predicted response of the second modified industrial automation system under a second set of operating conditions, based on the second modified simulation model, and wherein, based on the second predicted response, the performance enhancement component is configured to determine whether performance of the second modified industrial automation system satisfies a defined performance criterion relating to a favorable operational performance of the second modified industrial automation system.
8 . The system of claim 6 , wherein the performance enhancement component is configured to generate a set of instructions or a recommendation message relating to the second modification and communicate the set of instructions or the recommendation message to at least one of a device of the set of devices, the user, or another user associated with the industrial automation system, to facilitate implementation of the second modification relating to the second performance of the third action.
9 . The system of claim 1 , wherein the performance enhancement component is configured to determine operational responses of a device of the set of devices under various operating conditions over a period of time and, based on the operational responses of the device, generate a virtual device that simulates or emulates operation of the device under the various operating conditions, and wherein the virtual device is usable in the simulation model that corresponds to the industrial automation system to simulate performance of the device or the industrial automation system under the various operating conditions.
10 . The system of claim 1 , wherein the computer-executable components further comprise: a data store configured to store information comprising the set of data associated with the set of devices, result data determined, derived, or obtained from the first analysis and the second analysis of at least the portion of the set of data, or simulation data relating to the first simulation and the second simulation, wherein the result data relates to results, comprising the first result and the second result, of the first analysis and the second analysis of at least the portion of the set of data, and wherein at least one of the collection component, the data store, or the performance enhancement component is part of a cloud platform; and an interface component configured to interface the cloud platform with the industrial automation system via a cloud gateway device of the industrial automation system to facilitate receiving, by at least one of the collection component, the data store, or the performance enhancement component, the set of data from the industrial automation system.
11 . The system of claim 1 , wherein the collection component is configured to receive a subset of the set of data from a set of sensor components associated with the industrial automation system or a group of users associated with the industrial automation system, wherein the group of users comprises the user, and wherein the set of sensor components is configured to sense conditions associated with the industrial automation system or the group of users, and generate the subset of the set of data based on the conditions associated with the industrial automation system or the group of users.
12 . The system of claim 1 , wherein the set of data relates to an industrial device of the set of devices, an industrial process associated with the set of devices, an industrial asset associated with the industrial automation system, a network-related device of the set of devices that facilitates data communications associated with the industrial automation system, an operating system associated with the industrial automation system, software associated with the industrial automation system, firmware associated with the industrial automation system, a group of users, comprising the user, associated with the industrial automation system, a communication device associated with the user, or at least one customer entity associated with the industrial automation system.
13 . A method, comprising: based on a first result of a first analysis of at least a portion of a set of data associated with a set of devices of an industrial automation system, generating, by a system comprising at least one processor, a simulation model representative of the industrial automation system that simulates performance of a first work action of a user in connection with a work task being performed by the user under a first instruction in connection with operation of the industrial automation system; determining, by the system, a modification of the first instruction to a second instruction relating to automated performance of a second work action in connection with the work task; based on a second result of a second analysis of the portion of the set of data and modification data relating to the modification, generating, by the system, a modified simulation model representative of a modified industrial automation system, comprising the modification of the first instruction to the second instruction for modified operation of the industrial automation system, wherein the modified simulation model simulates the automated performance of the second work action by a subset of devices as part of the work task under the second instruction; determining, by the system, a predicted response of the modified industrial automation system under a set of operating conditions, based on the modified simulation model relating to the second instruction; and in response to determining, based on the predicted response of the modified simulation model, that, under the second instruction, the subset of devices is able to emulate the performance of the work task by the automated performance of the second work action and improve operational performance of the industrial automation system over the first instruction, performing, by the system, the modification of the first instruction to the second instruction to have the automated performance of the second work action by the subset of devices, under the second instruction, in connection with the work task, in place of the user, wherein the subset of devices is part of or incorporated into the set of devices.
14 . The method of claim 13 , further comprising: based on the second result, designing, by the system, executable code that enables the automated performance of the second work action by the subset of devices in place of the user, in accordance with the second instruction; and to facilitate the designing, simulating, by the system, operation of the subset of devices, based on the executable code, to verify that the subset of devices is able to execute the automated performance of the second work action in accordance with a defined performance criterion relating to a defined favorable performance result of the modified industrial automation system, wherein the portion of the set of data is representative of, and is obtained from monitoring of, the performance of the first work action by the user, comprising an interaction of the user with the industrial automation system during the performance of the work task by the user, that occurred prior to the designing of the executable code and the automated performance of the second work action by the subset of devices.
15 . The method of claim 14 , further comprising: determining, by the system, a correlation between the performance of the first work action by the user and a defined favorable performance result of the industrial automation system, based on the first result of the first analysis of at least the portion of the set of data.
16 . The method of claim 15 , wherein the first analysis of at least the portion of the set of data comprises analyzing action data relating to the first work action and how the performance of the first work action correlates with the defined favorable performance result of the industrial automation system, and wherein the method further comprises: based on the second result of the second analysis, determining, by the system, that the subset of devices is able to execute the automated performance of the second work action that emulates and improves upon the performance of the first work action of the user in connection with the operation of the industrial automation system; based on the designing of the executable code, generating, by the system, the executable code that emulates the performance of the second work action; and modifying, by the system, the industrial automation system to incorporate the executable code into the industrial automation system to facilitate the automated performance of the second work action by having the subset of devices, based on the executable code, execute the automated performance of the second work action in the modified industrial automation system in place of the user.
17 . The method of claim 14 , further comprising: implementing, by the system, the subset of devices in the industrial automation system to perform the second work action based on execution of the executable code.
18 . The method of claim 13 , further comprising: interfacing, by the system, the cloud platform with a group of cloud gateway devices of the industrial automation system; monitoring, by the system, the industrial automation system via the interfacing of the cloud platform with the group of cloud gateway devices; based on the monitoring, receiving, by the system, the set of data from the industrial automation system via the interfacing; and storing, by the system, the set of data in a data store located in a cloud platform.
19 . A non-transitory machine-readable medium storing executable instructions that, in response to execution, cause a system comprising at least one processor to perform operations, comprising: based on a first result of a first analysis of at least a portion of a set of data associated with a set of devices of an industrial automation system, generating a simulation model of the industrial automation system that simulates performance of a first action of a user with regard to a work task being performed by the user under a first instruction and relating to operation of the industrial automation system; determining a modification of the first instruction to a second instruction relating to automated performance of a second action with regard to the work task; based on a second result of a second analysis of the portion of the set of data and modification data relating to the modification, generating a modified simulation model of a modified industrial automation system, comprising the modification of the first instruction to the second instruction for modified operation of the industrial automation system, wherein the modified simulation model simulates the automated performance of the second action by a subset of devices with regard to the work task under the second instruction; predicting a response of the modified industrial automation system under a set of operating conditions, based on operation condition data applied to the modified simulation model relating to the second instruction, wherein the operation condition data is representative of the set of conditions; and in response to determining, based on the predicting of the response of the modified industrial automation system, that, under the second instruction, the subset of devices is able to emulate performance of the work task by the automated performance of the second action and enhance operational performance of the industrial automation system over the first instruction, performing the modification of the first instruction to the second instruction to have the automated performance of the second action by the subset of devices, under the second instruction, with regard to the work task, in place of the user, wherein the subset of devices is part of or incorporated into the set of devices.
20 . The non-transitory machine-readable medium of claim 19 , wherein the operations further comprise: based on the second result, determining a design of executable code that enables the automated performance of the second action by the subset of devices in place of the user, in accordance with the second instruction; in connection with the determining of the design of the executable code, simulating operation of the subset of devices, based on the executable code, to verify that the subset of devices is able to execute the automated performance of the second action in satisfaction of a defined performance criterion relating to a defined favorable performance result; and in response to the determining of the design of the executable code, and in response to verifying that the subset of devices is able to execute the automated performance of the second action in satisfaction of the defined performance criterion, generating the executable code, wherein the subset of devices is implemented as part of the modified industrial automation system to execute the automated performance of the second action in response to execution of the executable code.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of, and claims priority to each of, U.S. patent application Ser. No. 17/223,385 (now U.S. Pat. No. 11,676,508), filed Apr. 6, 2021, and entitled “USING CLOUD-BASED DATA FOR INDUSTRIAL AUTOMATION SYSTEM TRAINING,” which is a continuation of, and claims priority to each of, U.S. patent application Ser. No. 15/714,333 (now U.S. Pat. No. 10,984,677), filed Sep. 25, 2017, and entitled “USING CLOUD-BASED DATA FOR INDUSTRIAL AUTOMATION SYSTEM TRAINING,” which is a continuation of, and claims priority to each of, U.S. patent application Ser. No. 14/087,922 (now U.S. Pat. No. 9,786,197), filed Nov. 22, 2013, and entitled “USING CLOUD-BASED DATA FOR INDUSTRIAL AUTOMATION SYSTEM TRAINING” (amended to “USING CLOUD-BASED DATA TO FACILITATE ENHANCING PERFORMANCE IN CONNECTION WITH AN INDUSTRIAL AUTOMATION SYSTEM”), which claims priority to U.S. Provisional Patent Application Ser. No. 61/821,639, filed on May 9, 2013, and entitled “REMOTE SERVICES AND ASSET MANAGEMENT SYSTEMS AND METHODS,” the entireties of which applications are hereby incorporated herein by reference. TECHNICAL FIELD The subject application relates generally to industrial automation, e.g., to using cloud-based data to facilitate enhancing performance in connection with an industrial automation system. BACKGROUND INFORMATION Industrial automation systems can perform various processes to produce desired products or processed materials. An industrial control system can comprise various industrial devices, industrial processes, other industrial assets, and network-related assets (e.g., communication network devices and software). Industrial controllers and their associated input/output (I/O) devices can be useful to the operation of modern industrial automation systems. These industrial controllers can interact with field devices on the plant floor to control automated processes relating to such objectives as product manufacture, material handling, batch processing, supervisory control, and other such applications. Industrial controllers can store and execute user-defined control programs to effect decision-making in connection with the controlled process. Such programs can include, but are not limited to, ladder logic, sequential function charts, function block diagrams, structured text, or other such programming structures. In general, industrial controllers can read input data from sensors and metering devices that can provide discreet and telemetric data regarding one or more states of the controlled system, and can generate control outputs based on these inputs in accordance with the user-defined program. In addition to industrial controllers and their associated I/O devices, some industrial automation systems also can include low-level control systems, such as vision systems, barcode marking systems, variable frequency drives, industrial robots, and the like, which can perform local control of portions of the industrial process, or which can have their own localized control systems. Operators and other users can interact with industrial automation systems, for example, to facilitate performing manual operations to facilitate operation of an industrial automation system and/or monitoring or managing machines or processes associated with the industrial automation system. For example, operators and other users can interact with (e.g., work with, monitor, manage, etc.) industrial devices, industrial processes, control programs, human machine interfaces (HMIs), etc., associated with the industrial automation system, to facilitate operation of the industrial automation system. Some operators or users can have more experience than other operators or users, which often can translate into the more experienced operators or users being better performing operators or users in connection with the industrial automation system. Also, regardless of the amount of experience in industrial automation, some operators or users can perform better than other operators or users with respect to the industrial automation system. As a result, an industrial automation system, or portion thereof, typically can operate more efficiently when certain operators or users (e.g., more experienced or better performing operators or users) are working with, monitoring, or managing the industrial automation system, or portion thereof, than when other operators or users (e.g., less experienced or lower performing operators or users) are working with, monitoring, or managing the industrial automation system, or portion thereof. The above-described deficiencies of today's industrial control and business systems are merely intended to provide an overview of some of the problems of conventional systems, and are not intended to be exhaustive. Other problems with conventional systems and corresponding benefits of the various non-limiting embodiments described herein may become further apparent upon review of the following d